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OBJ-2-MAP V1.1
So I added a few new features to my OBJ-2-MAP utility and put together a small web page explaining how to use it.

This is a utility that can take OBJ files exported from any modeling app and convert the geometry inside into Quake brushes.

http://www.wantonhubris.com/obj-2-map/

Have at it! I think everything will work.

[edit: updated url]
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Warren 
JackJazz will miss you.
^v^ 
Doesnt Export On Extrusion 
Hey there,
I've been looking for something like this for quite a while for mapping with COD: WaW and COD 4, but I just cant get it to work the way I want. It seems "extrusion" is more than likely the mode I'd want to use (as I want to recreate a map from a 3D model. I've used OBJ exporter for 3DSmax 2015 which seems to have exported properly. I've removed all textures (as I don't mind re-texturing), so in OBJ2MAP i've typed caulk in place of DEFAULT so COD WaW Radiant will read it. Unfortunately due to the conversion process, it's just got too massive in scale, and there is no option to reduce scale on OBJ2MAP.
Any ideas ?
Thanks in advance. 
... 
I totally must have had a mans look. Just saw the "scale" % field. It still crashes at Extrusion though (Unhandled Exception). It makes me have to exit the program and re-load it, otherwise the log file is "in use" by another process. 
 
That's odd. Does "Spikes" crash as well? That might work for something modeled in Max as well.

Also, try checking or unchecked the 'axis aligned' box and see what happens. 
Crashes on Spikes as well. Tried both combinations (with and without axis aligned box) and it does the same thing. I wonder if its Windows 10 related...or maybe I need some Runtime files that you have and I don't.

************** Exception Text **************
System.NullReferenceException: Object reference not set to an instance of an object.
at OBJ2MAP.XVector.Multiply(XVector _V, Double _Scalar)
at OBJ2MAP.MainForm.GoButton_Click(Object sender, EventArgs e)
at System.Windows.Forms.Control.OnClick(EventArgs e)
at System.Windows.Forms.Button.OnClick(EventArgs e)
at System.Windows.Forms.Button.OnMouseUp(MouseEventArgs mevent)
at System.Windows.Forms.Control.WmMouseUp(Message& m, MouseButtons button, Int32 clicks)
at System.Windows.Forms.Control.WndProc(Message& m)
at System.Windows.Forms.ButtonBase.WndProc(Message& m)
at System.Windows.Forms.Button.WndProc(Message& m)
at System.Windows.Forms.NativeWindow.Callback(IntPtr hWnd, Int32 msg, IntPtr wparam, IntPtr lparam)
______________________

All I'm getting when I get it to make a map (which takes bloody ages) is a bunch of jumbled (but joined) brushes which I can only manage to load into trenchbroom (although i'm trying to get it into COD Radiant. There is no pattern there, it's just a jumbled mess.

Radiant throws a fit and tells me it's missing a { no matter how many times I compile it.

I think maybe I'm just expecting too much from this..single models it will no doubt work, but a whole map is probably just too much for it to handle. 
 
How many faces is your model? I was able to convert a whole map's worth of geometry for terrain without problems from obj2map, so it might be something else. I used max 2009, possibly the obj format is a little different in 2015? 
Summary:
Vertices: 33410
Faces: 12
Brushes: 202

It is possible that the obj is getting corrupt in the conversion process I suppose, but I can load it perfectly into windows 10 3d builder and Blender. I can not get anything to export the .map's properly though. 
Jon 
Which build of obj2map was that with? Maybe try the beta in post 66; I remember fixing a bug with a similar stack trace as what you posted. 
Both versions (1 and 1.1.1) did the same thing. I'll try this beta (extrusion\grid align locked it up to a "not responding" state), so I'll try the other combinations and let you know 
Standard\axis aligned : Stuck on "Adding brush 0 to map" - Not Responding -..took 40 mins to get the brush 1

extrusion\axis aligned : Stuck on "Adding brush 0 to map" - Not Responding

extrusion\no axis aligned : Unhandled Exception
System.ArgumentOutOfRangeException: Index was out of range. Must be non-negative and less than the size of the collection.
Parameter name: index

Spikes\axis aligned : Stuck on "Adding brush 0 to map" - Not Responding

Spikes\no axis aligned : Unhandled exception - The path is notof a legal form. 
I'm going to try 3DSmax 2009 and see what happens with THOSE OBJ's. 
Ok, installed 3dsmax 2009, Re-ripped and exported the OBJ again (successfully). Same errors as before. Must be Windows 10 related. I'll try on other PC's around the home when I get a chance 
 
OBJ is an ascii format. Open it and check it. 
 
Or post the file here. Maybe someone can figure out what's going on. 
 
Summary:
Vertices: 33410
Faces: 12
Brushes: 202


I mean what were the stats in Max. Also the above numbers don't make any sense. 12 faces with 33k verts?

As a reference, I was successfully able to convert a mesh with 5k triangles and 2.5k verts into a map file from Max2011 (sorry, i said 2009 earlier). 
 
Try to triangulate whole model and see if it works. 
I've uploaded the file to my ftp. Now please note, this is a private project, and the contents DO infringe copyright. So please delete it once you're done, as it's not mine to distribute. I'll be deleting the file off the ftp in 24 hours.
www.leviathan.net.au/nuke-rebuilt.obj 
That Mesh Is Kinda Messed Up 
I have a hard time seeing it ending up as a map file at all. 
That's what the OBJ converter does from 3DSmax 2009 and 2016. It loads fine into Win10 3D builder and blender, but as far as map conversion..I think i've hit a wall. (so to speak) :) 
Imported The Obj Into Blender 
Mesh is just a massive cloud of orphaned vertices.

I'm all for experimental maps and whatnot, but... 
There Are Triangles There 
Try zooming out 
 
I looked at that OBJ. That's never going to convert. That's insane. 
And Where's It From? 
I'm guessing from the googie look and file name it's something Fallout related? 
 
I mean, maybe break it down into smaller chunks or something but :

(a) it's absolutely immense - MODO tells me there's ~163,000 triangles

(b) there's a mountain of triangles (none of which are anywhere near a grid, I'd wager)

(c) I think it broke when loading into MODO, to be honest, as there are missing polys everywhere, tons of overlapping stuff, etc.

Just ... bleh. 
 
The idea behind this app is that you're modeling with Quake in mind. :) 
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